Solder replacement by conductive tape material

Abstract

A method of forming a solar device. The method includes providing one or more photovoltaic cells having a front surface region and a back surface region. The method includes providing a first conductor element having a first side operably coupled to a first region of the front surface region of the one or more photovoltaic cells and a second side. In a specific embodiment, the conductor element includes a first anisotropic conducting tape material or a first conducting tape material, the first conducting element having a first thickness, a first length, and a first width. The method performs a bonding process to cause the first conductor element to conduct electric current in a first selected direction.

1 . A method of forming a solar device, comprising:
 providing one or more photovoltaic cells, the one or more photovoltaic cells comprising a front surface region and a back surface region;   providing a first conductor element having a first side operably coupled to a first region of the front surface region of the one or more photovoltaic cells and a second side, the conductor element comprising a first anisotropic conducting tape material or a first conducting tape material, the first conducting element having a first thickness, a first length, and a first width; and   performing a bonding process to cause the first conductor element to conduct electric current in a selected direction.   
     
     
         2 . The method of  claim 1  further comprises providing a second conductor element comprising a third side operably coupled to a second region of the backside surface region of the one or more photovoltaic cells and a fourth side, the second conductor element being provided using a second anisotropic conducting material or a second conducting tape material, the second conducting element having a second thickness, a second length, and a second width 
     
     
         3 . The method of  claim 1  wherein the solar device is free of a solder material. 
     
     
         4 . The method of  claim 1  wherein the one or more photovoltaic cells comprises a material selected from CIGS, cadmium telluride, amorphous silicon, or other semiconductor materials. 
     
     
         5 . The method of  claim 1  wherein the one or more photovoltaic cells comprises a silicon based single crystal or polycrystalline solar cell. 
     
     
         6 . The method of  claim 1  wherein the respective anisotropic conducting material comprises an anisotropic conducting characteristics provided by trapping a plurality of anisotropic conductive particles within the respective conductor element and the respective surface region of the one or more photovoltaic cells. 
     
     
         7 . The method of  claim 1  wherein the first conductor element and the second conductor element each has a width ranging from about 0.5 mm to about 15 mm. 
     
     
         8 . The method of  claim 6  wherein each of the plurality of conductive particles comprises one or more metal layers cladded between a substantially spherically polymer particle and an insulating layer. 
     
     
         9 . The method of  claim 6  wherein the respective anisotropic conductive material provides electrical conduction along a direction of the respective thickness of the respective anisotropic conductive material after the bonding process. 
     
     
         10 . The method of  claim 8  wherein the one or more metal layers comprise nickel and gold. 
     
     
         11 . The method of  claim 9  further comprises a third conductor layer coupled to the second side of the of the first conductor element and a fourth conductor layer coupled to the fourth side of the of the second conductor element. 
     
     
         12 . The method of  claim 11  wherein the third conductor layer and the fourth conductor layer comprises a metal material, the metal material being selected from: copper, gold, silver, or aluminum. 
     
     
         13 . The method of  claim 1  wherein the one or more photovoltaic cells further comprises a plurality of concentration elements coupled to respective plurality of photovoltaic regions. 
     
     
         14 . The method of  claim 1  wherein the one or more photovoltaic cells are sealed between a transparent substrate member and a back cover member. 
     
     
         15 . The method of  claim 1  wherein the bonding process comprising a pressure process and/or a thermal process, the bonding process causing the one or more metal layers of each of the anisotropic conducting particles to be exposed in selected areas allowing electrical conduction along the direction of the thickness of the first conductor element and the direction of the thickness of the second conductor element. 
     
     
         16 . The method of  claim 15  wherein the pressure process s provided at a pressure ranging from about 0.8 kg per cm 2  to about 5 kg per cm 2 . 
     
     
         17 . The method of  claim 15  wherein the thermal process is provided at a temperature ranging from about 50 Degree Celsius to about 150 Degree Celsius. 
     
     
         18 . The method of  claim 15  wherein the bonding process is provided for between 0.5 and 50 seconds. 
     
     
         19 . The method of  claim 1  wherein the anisotropic conducting particles are provided in a pressure sensitive adhesive material. 
     
     
         20 . A solar cell device, comprising:
 one or more photovoltaic cells, the one or more photovoltaic cells comprising a front surface region and a backside surface region, and   a first conductor element comprising a first side operably coupled to a first region of the front surface region of the one or more photovoltaic cells and a second side, the first conductor element being provided using a first anisotropic conducting tape material, the first conducting element having a first thickness, a first length, and a first width.   
     
     
         21 . The solar device of  claim 20  further comprises a second conductor element comprising a third side operably coupled to a second region of the backside surface region of the one or more photovoltaic cells and a fourth side, the second conductor element being provided using the anisotropic conducting tape material, the second conducting element having a second thickness, a second length, and a second width. 
     
     
         22 . The solar device of  claim 20  wherein the anisotropic conducting tape material comprises an anisotropic conducting characteristics provided by trapping a plurality of conductive particles between the respective conductor element and the respective surface region of the one or more photovoltaic cells. 
     
     
         23 . The solar device of  claim 20  wherein the first conductor element and the second conductor element each has a width ranging from about 0.5 mm to about 15 mm. 
     
     
         24 . The solar device of  claim 22  wherein each of the plurality of conductive particles comprises one or more metal layers cladded between a substantially spherically polymer particle and an insulating layer. 
     
     
         25 . The solar device of  claim 24  wherein the one or more metal layers comprise nickel and gold. 
     
     
         26 . The solar device of  claim 22  wherein the respective conductive elements provide electrical conduction along a direction of the respective thickness of the respective conductive element. 
     
     
         27 . The solar device of  claim 22  further comprises a third conductor layer coupled to the second side of the of the first conductor element and a fourth conductor layer coupled to the fourth side of the of the second conductor element, the third conductor layer and the fourth conductor layer comprises a metal material, the metal material being selected from: gold, silver, copper, or aluminum. 
     
     
         28 . The solar device of  claim 20  wherein the one or more photovoltaic cells further comprises a plurality of concentration elements coupled to respective plurality of photovoltaic regions. 
     
     
         29 . The solar device of  claim 20  wherein the one or more photovoltaic cells, including the respective conductor elements and electrical interconnects are sealed between a transparent substrate member and a back cover member.